JPH08127950A - Production of wadding - Google Patents

Abstract

PURPOSE: To provide a method for mechanically mass-producing a mattress having a thick hip seat in producing the mattress having the thick part where a hip touches of a sleeper. CONSTITUTION: A thin web sheet 10 having a required width is produced with a carding engine 2 and conveyed onto a swinging down conveyor 4 using a carrying conveyor 3. The web sheet is then advanced in the longitudinal direction while swinging down the sheet onto a control conveyor 5 at a constant swinging width with the shaking down conveyor 4 to continuously form a zigzag sheet 11, which is then pulled and cut to a required length with a cutting roller 6. A prescribed number of the cut sheets are subsequently superposed by repeating the advancing and retreating movement of a web conveyor 7 and then pressed to a moderate thickness with a pressing conveyor 8. The swinging down of the web sheet 10 is simultaneously changed into a required swinging width and a required swinging position in a required timing at that time to continuously form the zigzag sheet having a partially different width. Thereby, a wadding having a partially different thickness is formed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in a method for manufacturing futon cotton, and more specifically, a new method for mechanically mass-producing thick futon cotton used when making a bedding which has a thick portion where the buttocks of the sleeping person touch. It is about the method.

[0002]

2. Description of the Related Art A futon, which has been used for a long time,
The part where the buttocks hit is dented by the continuous heavy pressure and deformed into a very uncomfortable state, and also causes physical damage such as low back pain. For this reason, conventionally, a method has been adopted in which the portion of the cotton to be hit by the buttocks is thickened in advance.

However, in the conventional futon-cotton molding apparatus, if the rotational speeds of the respective machine parts are set, these cannot be changed during operation, and only the molded-cotton cotton of a fixed size is always produced. I couldn't. for that reason,
Up to now, in order to make a duvet with a thick buttocks (hereinafter referred to as a fluffy duvet), it is necessary to first manufacture a pressure-equaling duvet and then use a supplementary cotton prepared separately for this duvet. A method of manually sandwiching it in various places was adopted.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the fact that the conventional method for producing thick-puffer futon is manual and inefficient, and it is continuously produced mechanically in mass production. The technical problem is to provide a new method that can be done.

[0005]

In order to achieve the above object, according to the present invention, the respective machine parts constituting the bedding forming apparatus are comprehensively controlled by a control device by applying a sensor or the like to make a preliminary input. It realizes a method for surely obtaining thick fluffy cotton according to the set specifications.

That is, according to the present invention, raw cotton is formed into a web sheet by a card machine, the web sheet is swung down with a constant swing width, and the web sheet is advanced in the length direction to continuously form a folded sheet. In order to form a futon cotton by forming a blanket, cutting it into a certain length and stacking it, a. An operation of forming the kudzu folding sheet with a predetermined basic width, b. By changing the swing-down of the web sheet to a desired swing width and a target swing position at the same time to form a folded sheet having different widths and positions at a predetermined timing The point is that the technical problems described above are solved by adopting a means of continuously forming different fold sheets and then cutting and stacking the sheets in a required length.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in more detail with reference to the embodiments shown in the accompanying drawings. First, as shown in FIG. 1, a conventionally known card machine 2 is used to form a thin web sheet 10 having a required width, and this is conveyed by a conveyor 3 to a position above the conveyor 4, and the conveyor 4 is moved down. Reprinted to. This swing-down conveyor 4
As shown in FIG. 2, since the lower end portion 43 is a mechanism for swinging while always maintaining the parallel position with respect to the surface of the control conveyor 5, the upper end portion 44 repeatedly moves up and down in the vertical direction. Therefore, the conveyer conveyor 3 has a two-stage structure of the upper conveyer 31 and the lower conveyer 32, and the upper conveyer 31 is swung to follow the vertical movement so that the cutting of the web sheet 10 can be prevented. There is.

The swing-down conveyor 4 is composed of two conveyors 41 and 42 facing each other, and these conveyors are closely arranged in parallel with each other.
The structure is such that while the supplied web sheet 10 is clamped with an appropriate pressure, the web sheet 10 is fed downward by the rotation thereof and simultaneously swung. The swing width and swing position of this swing-down conveyor 4 can be controlled even during operation, and swinging at the required swing width and swing position
The web sheet 10 can be swung down on the control conveyor 5.

The control conveyor 5 is
Move forward and circulate at the required speed. On the other hand, since the swing-down conveyor 4 swings in a direction orthogonal to the moving direction of the control conveyor 5, the swing-down web sheets 10 are stacked in a zigzag shape to form a zigzag sheet 11. The sheet is conveyed onto a sheet conveyor 7 via a cutting roller 6 composed of a pair of front rollers 61 and a pair of back rollers 62.

The sheet conveyor 7 is composed of a pair of front conveyors 72 and back conveyors 71 which are faced to each other on the same plane, and each is independently reversibly controlled to rotate. At this time, the laying length of the folding sheet 11 on the control conveyor 5 is measured by the rotation amount of the control conveyor 5 and sent to the control device. The length of passage of the back roller 61 is also measured, and the signal of the measured value is constantly sent to the control device.

The kudzu folding sheet 11 that hangs down after passing through the cutting roller 6 is a front sheet of the cutting roller 6.
The roller 62 is pulled by the temporarily increased speed rotation and cut into a predetermined length to form the cut sheet 12,
The sheet conveyor 7 is stacked and laid on the surface of the conveyor 7 by repeating the forward movement circulation movement and the backward rotation, and a predetermined number of sheets are stacked to form the multiple sheets 13.

When the formed multiple sheet 13 is advanced most, it is advanced as it is, pressed by the press conveyor 8 to an appropriate thickness, and sent to the subsequent step (not shown). Then, in the subsequent step, the multiple sheets 13 are folded so as to wrap them and the futon cotton 14 is completed (see FIG. 3). Meanwhile, kudari sheet
The 11 items are being sent out continuously.

Then, the present apparatus is comprehensively controlled by the control apparatus which inputs the preset set value. The control device compares the rotation amount and the set value of the control conveyor 5 sent to the control device, and the control device issues an instruction to change or return the swing width and swing position of the swing-down conveyor 4 and the same is sent. The cut amount of the folding sheet 11 is issued by comparing the rotation amount of the back roller 62 and the set value. In this way, the apparatus can obtain the multiple sheets 13 in which the cut sheets 12 having different widths are sandwiched and finally obtain the bottom thick futon having a large amount of cotton.

That is, raw cotton is formed on the web sheet 10 by the card machine 2, and while the web sheet 10 is being swung down with a constant swing width, the wrinkle sheet 11 is continuously formed, and this is fixed. In the case of manufacturing futon cotton by cutting into long lengths and stacking them, the web sheet 10 is swung down at the required timing at the required swing width and the required swing position at the same time, and the width of the required length is different. After continuously forming folded sheets, return to the initial swing width and swing position again in an arbitrary combination to continuously form a folded sheet with different widths and cut it to the required length for stacking. As a result, it is possible to obtain bottom thick futon with different thicknesses at required locations.

Further, a card machine 2 for forming the raw cotton on the web sheet 10, a conveyor 3 for lowering and conveying the web sheet 10 formed and discharged by the card machine 2 to the conveyor 4, and the conveyor 3 A control conveyor that lowers the conveyed web sheet 10 onto a control conveyor 5 and adjusts the thickness of the swing-down conveyor 4 and the folding sheet 11 that is formed by being swung down from the swing-down conveyor 4. 5, a cutting roller 6 that pulls and cuts the folding sheet 11 sent by the control conveyor 5 to a required length, and a cutting roller 6 that is pulled and cut by the cutting roller 6.
A sheet conveyor 7 for stacking the sheets 12 by repeating forward and backward movements and then feeding the stacked cut sheets 12 to a press conveyor 8.
The press conveyor 8 that presses the multiple sheets 13 formed by being stacked on the sheet conveyor 7 and sends them to the subsequent process while forming a bottom thick futon cotton forming apparatus as a whole. Therefore, in the present embodiment, the web discharging speed of the card machine 2, the transfer conveyor 3, the swing-down conveyor 4, and the control conveyor 5 are used.
The rotation speed of each of the cutting roller 6, the sheet conveyor 7, and the press conveyor 8 is initialized by a setting device in the control device, and at the same time, the swing width and swing position of the swing-down conveyor 4 and the cut position are set.・ Increased rotation of the front roller 62, which constitutes the roller 6, and the front conveyor 72 and back, which constitutes the sheet conveyor 7.
The rotation direction of the conveyor 71 is also controlled by the control device,
Control conveyor 5 and back roller 61
Is also configured to be measurable, and these mechanical parts are integrated by the control device as a whole.

[0016]

The operation according to the present invention will be described with reference to the drawings together with the embodiments. As shown in Figure 4, length is now 300 cm and width is 2.
Five cut sheets 12a with a basic width of 00 cm are stacked, and then two cut sheets 12b with a width of 300 cm and a width of 70 cm are changed.
50 pieces from the lower end of the basic width cut sheet 12a in the width direction
At the position of cm, the modified width cut sheets 12b are stacked in parallel so that the lower ends in the width direction are positioned, and another basic width cut sheet 12a is further stacked to form a multiple sheet 13, which is shown in FIG. As shown in FIG. 3, an example in which 20 pieces of 100 cm × 200 cm molded duvet cotton 14 are finally manufactured by folding them into 3 pieces so as to wrap them will be described.

The production speed of the thick fluffy cotton 14 by this device is
The web discharge speed discharged from the card machine 2 is the basis. This discharge speed is determined, the speed of the transport conveyor 3 is determined,
The rotation speed of the swing-down conveyor 4 and the swing speed (= the moving speed of the tip end portion of the swing-down conveyor 4) are determined. Also, by setting the swing width 4a of the swing-down conveyor 4, the width of the folding sheet 11 is controlled by the conveyor 5
The thickness is determined by the speed setting.

When the speed of the control conveyor 5 is increased, the folding angle becomes large as shown in FIG. 1, the overlapping portion becomes small and the folding sheet 11 becomes thin. Further, the rotation speed of the cut roller 6, the speed of the sheet conveyor 7, and the speed of the press conveyor 8 are determined according to the speed of the control conveyor 5. The rotational speed of each machine unit can be finely adjusted for each machine unit.

Next, in order to operate this device in a required order, a required set value is input to a control device (not shown). In this device, various multi-layered sheets 13 in which cut sheets 12 of various sizes are stacked in a predetermined order can be obtained by inputting data to the control device. That is, the control device has a lot number N, a width W, a length L, the number of cuts C,
The swing start position (P) and the number of multiple sheets (TS) are input.

In this embodiment, five basic width cut sheets 12a are piled up.
1, the size (W1; 200, L1; 300), the number of cuts C1; 5), and the swing start position (P1; 0) are input. In this case, the swing start position of the basic width cut sheet 12a is 0.
Shall be kept.

In this embodiment, the modified width cut sheet 12b
Since two sheets are stacked, this is designated as lot number N2, and the size (W2; 70, L2; 300), the number of cuts (C2; 2),
Input the swing start position (P2; 50). Finally, one basic width cut sheet 21a is overlaid, so this is designated as lot number N3, and the size (W3; 200, L3; 300), number of cuts (C3; 1), and swing start position (P3; 0) are input. Then, finally, the required number of multiple sheets 13 (TS; 20) is input.

Based on these inputs, the control device controls the laid length of the folding sheet for each lot, that is, the laid length T of the lot.
Calculate L and store each. [TL1; 1500 (300 x 5)] for lot number N1, [TL2; 600 (300 x 2)] for lot number N2, [TL3; 300 (300 x 1)] for lot number N3 The number of cut sheets manufactured at the same time and used for one multiple sheet 13, that is, the number of set cuts [SC; 8 (5 + 2 +
1)] is also calculated and stored.

Next, the card machine 2 and the transfer conveyor 3
, Swing-down conveyor 4, control conveyor 5, cutting roller 6, sheet conveyor 7
And the initial speed of the press conveyor 8 and the swing speed of the swing-down conveyor 4 are set in the drive units (not shown) of the respective constituent machine units. At the start of production, the card machine 2, the transfer conveyor 3 and the swing-down conveyor 4 start operating according to the instruction of the control device. However, the swing-down conveyor 4 starts only the rotation for feeding the web without swinging in a state of swinging to the end (swing start position 0).

Web sheet 10 ejected from card machine 2
Goes through the conveyor 3 and then the swing-down conveyor 4
The surface of the control conveyor 5 is reached from the tip.
At this time, in the present embodiment, an optical sensor (not shown) senses this, and the swing-down conveyor 4 starts swinging at the initial swing width (W1; 200) based on the instruction of the control device, and the control conveyor 5 Starts rotating.

Here, as shown in FIG. 2, the swing width 4a of the swing-down conveyor 4 is equal to the control conveyor 5
Sensors 51 and 52 installed on the left and right sides detect and control the lower end of the swing-down conveyor 4. That is, when the lower end of the swing-down conveyor 4 comes to the right side, the sensor 51 detects it and changes the swing direction. Similarly, when the lower end of the compare 4 comes to the left side, the sensor 52 detects this. Then, the direction is changed and continuous reciprocating swing is performed.

Specifically, the sensors 51 and 52 are both fixed to racks 53 and 54, and the racks 53 and 54 are both driven by motors 57 and 58 via pinions 55 and 56.
The motors 57 and 58 rotate forward and backward according to an instruction from a control device (not shown) to position the sensors 51 and 52. At the start of the operation of the illustrated device, the sensor position is set to the basic width position, and this basic position is set at the swing start position (P;
0) is stored.

The web sheet 10 is formed on the folding sheet 11 and sent out. At the same time, the rotation amount of the control conveyor 5 is detected by measuring the rotation angle of the rotation support shaft of the control conveyor 5 by an encoder (not shown) in this embodiment, and this signal is sent to the control device. Is converted into the moving length of the control conveyor 5 and stored as the production length of the kudzu folding sheet 11. Then, the tip of the kudzu folding sheet 11 is the cutting roller 6
In this embodiment, the optical sensor (not shown) detects that the front conveyor 62 reaches the nip point, and the back conveyor 71 of the sheet conveyor 7 starts to rotate backward.

At the same time, the back of the cutting roller 6
In the present embodiment, the rotation amount of the roller 61 is measured by an encoder (not shown) and sent to the control device, and the folding sheet
It is stored after being converted to a passage length of 11. Then, when the conversion correction value of the rotation amount of the back roller 61 reaches the set value (300 cm), a control device (not shown) outputs a command signal for temporary acceleration to the front roller 62 of the cut roller 6 to cause a conflict. The folded sheet 11 is pulled and cut into pieces, and at the same time, the entire sheet conveyor 7 starts moving forward.

Therefore, every time the passage length reaches 300 cm, a command signal is output from the control device, the cut roller 6 cuts the folding sheet 11, and the sheet conveyor 7 changes the rotation to make a basic change. Stack width cut sheets 12a. Then, each time a temporary speed-up instruction signal (cut instruction to the cut roller 6) is output to the front roller 62, 1 is subtracted from the number of cuts (C1; 5) of the lot N1. At the same time, 1 is also subtracted from the set / cut number (SC; 8). In this way, 1 is subtracted one after another. At this time, a control device (not shown) constantly monitors whether or not the production length of the folding sheet 11 reaches the lot laying length (TL1).

When the lot laying length (TL1) reaches the set value, 1500, the production of the folding sheet 11 shifts to the lot N2. The swing width of the swing-down conveyor 4 and the swing start position are changed according to the setting contents of the lot N2, and the production of the changed width folding sheet 11b is started. At this time, the control device determines from which position of the width of the Kuzuri sheet 11 to start changing the width by the change swing start position (P2; 50) and the dimension (W2; 70) that are previously input.・ Instructed to change the position of 52, which will start production of the changed width folding sheet. After that, when the number of cuts (C1) of the lot N1 becomes 0, the final cut of the lot N1 is completed and the lot N2 enters the cutting stage.

In this way, the lot production is continued one after another, and when the number of set / cut sheets (SC; 8) becomes 0, one multi-sheet 13 is completed, and the front conveyor 72 moves forward. An instruction is given, and the multiple sheets 13 are sent to the press conveyor 8 and sent to the subsequent process. At this time, 1 is subtracted from the number of multiple sheets (TS; 20). Then, the number of cuts (C), lot laying length (TL), and number of set cuts (SC) of the control device are returned to the initial values, and the production of the second multiple sheets 13 is started. Eventually, the number of multiple sheets (TS; 20) becomes 0, and the target 20 multiple sheets 13 are obtained.

[0032]

Since the present invention is constituted by the above method and apparatus, it has the following effects.

Since it is configured as a method of inputting the required data in advance to the control device and automatically manufacturing the fluffy thick bedding of the required shape according to the data, the production from raw cotton to fluffy thick bedding is unattended. It becomes possible continuously in a state close to
Labor saving and efficiency improvement of production can be achieved.

Data can be entered for each lot, and the number of cut sheets and the size can be designated for each lot, so that cut sheets of required dimensions can be stacked in the required order, and the required number of sheets can be overlapped. It is possible to easily obtain tail thick futon with a shape suitable for the purpose, such as the area of which can be set freely.

[Brief description of drawings]

FIG. 1 is an overall view of a molding device.

FIG. 2 is a rear view of the molding apparatus.

FIG. 3 shows a completed drawing of a molded comforter cotton.

FIG. 4 shows a stack of cut sheets.

[Explanation of symbols]

 2 Card Machine 3 Conveyor 4 Swing-down Conveyor 5 Control Conveyor 6 Cut Roller 7 Web Conveyor 8 Press Conveyor 9 Controller 10 Web Sheet 11 Kudori Sheet 12 Cut Sheet 13 Multiple Sheet 61 Front Roller 62 Back Roller 71 Front conveyor 72 Back conveyor

Claims (1)

[Claims] 1. A card machine is used to form raw cotton into a web sheet, and the web sheet is swung down at a constant swing width while being advanced in the longitudinal direction to continuously form a folded sheet. When forming a futon cotton by cutting it into a certain length and stacking it, a. An operation of forming the kudzu folding sheet with a predetermined basic width, b. By changing the swinging down of the web sheet to a desired swinging width and a target swinging position at the same time to form a folded sheet having different widths and positions at a predetermined timing A method for producing a molded cotton for a futon, which is characterized in that different kudzu sheets are continuously formed, further cut into a required length and stacked, and partially formed into a futon cotton having a different thickness.